Abstract: This invention relates to catalysts comprising a catalytic metal deposited on a composite support with well-dispersed chemical “anchor” species acting as nucleation centers for catalytic metal crystallites growth. The catalysts have the advantage that the average catalytic metal crystallite size can be controlled by the molar ratio of catalytic metal to chemical “anchor,” and is not limited by the porous structure of the support. A preferred embodiment comprises a cobalt-based catalyst on a silica-alumina support made by a co-gel method, wherein its average pore size can be controlled by the pH. The alumina species in the support most likely serve as chemical “anchors” to control the dispersion of cobalt species, such that the average cobalt crystallite size can be greater than the average pore size.

Abstract: This invention relates to methods and apparatus for separating liquid products and catalyst particles from a slurry used in a Fischer-Tropsch reactor system. The preferred embodiments of the present invention are characterized by a separation system that uses a sedimentation chamber, which contains at least one inclined channel that enhances the settling of particles within the slurry. The enhanced settling separates the slurry into a catalyst-rich bottom stream and a catalyst-lean overhead stream. The catalyst-rich bottom product stream is preferably recycled to the reactor, while the catalyst-lean overhead stream can be further processed by a secondary separation system to produce valuable synthetic fuels. The inclined channel may be provided by a structure selected from the group consisting of tube, pipe, conduit, sheets, trays, walls, plates, and combinations thereof.

Abstract: Methods and apparatus for removing wax products from a slurry used in a Fischer-Tropsch reactor. The preferred embodiments of the present invention are characterized by a solid/liquid separation system that removes liquid products from a slurry by drawing the fluid across a filter medium composed of a filter cake disposed on a substrate. In the preferred embodiments, the filter cake is desirable and performs the majority of the filtration. In certain embodiments, the filter medium is disposed in a filter housing where slurry flows parallel to the longitudinal axis of the filter medium from and inlet to an outlet. The characteristics or properties of the cake, which will effect the performance of the solid/liquid separation system, can be controlled by regulating the velocity of the slurry flowing across the cake, where the velocity may be regulated by adjusting the slurry flow through the filter housing or may be self-regulated by changing slurry velocities influenced by the design of the filter housing.

Abstract: Methods for producing clean liquid/wax products from a slurry used in a Fischer-Tropsch reactor are disclosed. In general, one embodiment of the present invention comprises a solid/liquid filtration system having a filter medium comprising a substrate and a filter cake deposited on the substrate, wherein the filter cake is generated by deposition of solids from the slurry. The thickness of the filter cake can be maintained within a desired range by controlling the slurry velocity and/or the pressure differential across the filter medium. This invention relates to a method of operation of such filtration system which increases filtration cycle time and improved filtrate quality resulting in very low solid content in filtrate.

Abstract: Methods and apparatus for separating liquid products and catalyst fines from a slurry used in a Fischer-Tropsch reactor. A settling system continuously or intermittently removes catalyst fines from the slurry and is coupled with catalyst-liquid separation system that separates liquid products from the slurry. The preferred separation system produces a sub-particle rich stream and a catalyst-lean stream that are removed from the system. The systems of the present invention act to reduce the concentration of catalyst fines in the reactor, thereby increasing the effectiveness of a catalyst-liquid separation system.

Abstract: This invention relates to methods and apparatus for separating liquid products and catalyst particles from a slurry used in a Fischer-Tropsch reactor system. The preferred embodiments of the present invention are characterized by a separation system that uses a sedimentation chamber, which contains at least one inclined channel that enhances the settling of particles within the slurry. The enhanced settling separates the slurry into a catalyst-rich bottom stream and a catalyst-lean overhead stream. The catalyst-rich bottom product stream is preferably recycled to the reactor, while the catalyst-lean overhead stream can be further processed by a secondary separation system to produce valuable synthetic fuels. The inclined channel may be provided by a structure selected from the group consisting of tube, pipe, conduit, sheets, trays, walls, plates, and combinations thereof.

Abstract: Methods and apparatus for separating liquid products and catalyst fines from a slurry used in a Fischer-Tropsch reactor. A settling system continuously or intermittently removes catalyst fines from the slurry and is coupled with catalyst-liquid separation system that separates liquid products from the slurry. The preferred separation system produces a sub-particle rich stream and a catalyst-lean stream that are removed from the system. The systems of the present invention act to reduce the concentration of catalyst fines in the reactor, thereby increasing the effectiveness of a catalyst-liquid separation system.

Abstract: Methods for producing clean liquid/wax products from a slurry used in a Fischer-Tropsch reactor are disclosed. In general, one embodiment of the present invention comprises a solid/liquid filtration system having a filter medium comprising a substrate and a filter cake deposited on the substrate, wherein the filter cake is generated by deposition of solids from the slurry. The thickness of the filter cake can be maintained within a desired range by controlling the slurry velocity and/or the pressure differential across the filter medium. This invention relates to a method of operation of such filtration system which increases filtration cycle time and improved filtrate quality resulting in very low solid content in filtrate.